Display packaging

ABSTRACT

The disclosure describes a method of manufacturing a display package ( 4 ) involving attaching thermoplastically coated cardboard sheets ( 5,6 ) together by fusing regions of the thermoplastic coating ( 8,9 ) together by high frequency welding. A container incorporating a mounting flange is also fused to the thermoplastic layers ( 8,9 ) by high frequency welding. There is no distinct adhesive between the polyethylene coated cardboard backing sheets.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefits of the earlier filed UK ApplicationSerial No. GB 0723894.2, filed 6 Dec. 2007, which is incorporated byreference for all purposes into this specification.

TECHNICAL FIELD

THE PRESENT INVENTION relates to display packaging, and moreparticularly relates to a method of manufacturing a display package, anda display package product.

BACKGROUND ART

Small, high value products, such as razor blades or memory cards, areoften held securely in a display package which allows the product to bedisplayed in a shop. The display package is usually substantially largerthan the product. This is for two reasons: (1) to provide space on thepackage to display information about the product, and (2) so that thesize of the packaged product is large enough to make it difficult for athief to steal and hide the packaged product without being noticed byshop security.

Display packaging is usually designed to be difficult to open tominimize the possibility of a thief opening a display package discretelyand stealing the contents.

One type of display package, commonly known as a “blister pack”, isformed from two shells of transparent plastic which are sealed together.The shells are sealed together in such a way that it is difficult for athief to pull the shells apart to gain access to a product retainedwithin the blister pack. Whilst blister packs can retain a productsecurely, there are problems with this type of packaging: (1) thepackaging is unattractive, and (2) the plastic material which forms theblister pack is not environmentally friendly to produce or dispose of.

FIG. 1 shows another type of prior proposed display package whichincorporates a backing sheet 1 and a display clam 2. The clam 2 is of atransparent plastics material and is shaped to receive a product. Theclam 2 defines an open end which is surrounded by a perpendicularlyextending mounting flange 3. The mounting flange 3 is mounted to thebacking sheet 1 with an adhesive to attach the clam 2 to the backingsheet 1. The backing sheet 1 thus seals the open end of the clam 2 toretain a product within the clam 2.

This other type of display package uses less plastic than a blister packand is thus more environmentally friendly than a blister pack. However,this type of display package is not secure because the adhesive does notattach the clam 2 to the backing sheet 1 securely. A thief can detachthe clam 2 from the backing sheet 1 easily to steal the product.

The pervasive practice when attaching two cardboard elements together toform a blister pack, clam pack or similar is to apply an adhesivebetween the two cardboard elements, apply pressure and heat the adhesiveto cure the adhesive and create a solid bond. This practice is fullyaccepted in the packaging world and the shortfalls in tidiness of join,waste materials generated, energy used to bring the join up totemperature are accepted by the industry. Temperatures of up to 400degrees Celsius are necessary to establish an acceptable bond. This hightemperature can cause problems if the article being packaged is affectedby heat. One cannot establish whether the packaged product has beenaffected by the heat application.

Embodiments of the present invention seek to provide a method ofmanufacturing a display package and a display package which is bothenvironmentally friendly and secure.

According to one aspect of the present invention, there is provided amethod of manufacturing a display package comprising: providing a firstcardboard element which has a region that is coated with a layer ofpolyethylene; providing a second cardboard element which has a regionthat is coated with a layer of polyethylene; positioning the first andsecond cardboard elements such that the coated regions at least partlyoverlap; and attaching the first cardboard element to the secondcardboard element by radio frequency (RF) welding at least part of theoverlapping coated regions such that the coated regions at least partlyfuse together.

Conveniently information is printed on the first cardboard element.

Preferably information is printed on the second cardboard element.

Conveniently the method further comprises: providing a third element;and positioning the third element between the first and second cardboardelements such that the third element is at least partly trapped betweenthe first and second cardboard elements when the first and secondsupport elements are attached to one another.

Advantageously the third element is of cardboard.

Preferably the first and second cardboard elements are each generallyplanar sheets, with one side of each of the sheets being substantiallyentirely coated with the layer of polyethylene.

In one embodiment the method further comprises: providing an open endedthermoplastic container which incorporates a mounting flange; placing aproduct into the container; positioning the mounting flange at leastpartly between the overlapping coated regions of the first and secondcardboard elements; and attaching the container to the cardboardelements by radio frequency (RF) welding at least part of the mountingflange to the coated regions such that the coated regions and themounting flange at least partly fuse together.

Preferably the method further comprises: inserting part of the containerthrough an aperture in the second cardboard element and positioning themounting flange so as to overlap part of the coated region of the secondcardboard element; and positioning the first cardboard element to closethe open end of the container such that the container is sealed whenfirst the cardboard element is attached to the second cardboard element.

According to a yet further aspect of the present invention, there isprovided a display package comprising: a first cardboard element whichhas a region that is coated with a layer of polyethylene; and a secondcardboard element which has a region that is coated with a layer ofpolyethylene; the first and second cardboard elements being attached toone another by at least part of the coated region of the first cardboardelement which is at least partly fused to at least part of the coatedregion of the second cardboard element.

Conveniently information is printed on the first cardboard element.

Preferably information is printed on the second cardboard element.

In one embodiment the display package incorporates a thermoplasticcontainer which is at least partly fused to the coated layer of thefirst cardboard element and the coated layer of the second cardboardelement.

SUMMARY OF THE INVENTION

The disclosure describes a method of manufacturing a display package (4)involving attaching thermoplastically coated cardboard sheets (5,6)together by fusing regions of the thermoplastic coating (8,9) togetherby high frequency welding. A container incorporating a mounting flangeis also fused to the thermoplastic layers (8,9) by high frequencywelding. There is no distinct adhesive between the polyethylene coatedcardboard backing sheets.

DESCRIPTION OF DRAWINGS

In order that the invention may be more readily understood, and so thatfurther features thereof may be appreciated, embodiments of theinvention will now be described, by way of example, with reference tothe accompanying drawings in which:

FIG. 1 is a diagrammatic perspective view of a prior proposed displaypackage,

FIG. 2 is a diagrammatic perspective view of parts of a display packagein accordance with a preferred embodiment of the invention,

FIG. 3 is a diagrammatic sectional view of part of the display packageof FIG. 1, during an initial stage of manufacture,

FIG. 4 is a view corresponding to FIG. 3, but at a later stage ofmanufacture,

FIG. 5 is a diagrammatic sectional view of another part of the displaypackage of FIG. 2, during an initial stage of manufacture,

FIG. 6 is a view corresponding to FIG. 5, but at a later stage ofmanufacture,

FIG. 7 is a diagrammatic perspective view of the display package of FIG.2 in a fully assembled form,

FIG. 8 is a diagrammatic perspective view of parts of a display packagein accordance with a further embodiment of the invention, and

FIG. 9 is a diagrammatic perspective view of the display package of FIG.8 in a fully assembled condition.

DESCRIPTION OF EMBODIMENTS

The present invention is a method and apparatus for display packaging.This disclosure describes numerous specific details in order to providea thorough understanding of the present invention. One skilled in theart will appreciate that one may practice the present invention withoutthese specific details. Additionally, this disclosure does not describesome well known items in detail in order not to obscure the presentinvention.

Referring now to FIG. 2 of the accompanying drawings, a display package4 in accordance with a preferred embodiment of the inventionincorporates a first support element in the form of a generally planarcardboard backing sheet 5. The display package 4 also incorporates asecond support element which is in the form of a generally planarcardboard front sheet 6. The front sheet 6 is provided with an aperture7.

A region of each of the front and backing sheets 5,6 is coated with arespective layer of thermoplastic 8,9, as shown in FIG. 3. In thispreferred embodiment the thermoplastic is polyethylene. The entirety ofone side of each of the sheets 5,6 is coated with the respective layerof thermoplastic 8,9. Each polyethylene coated cardboard backing sheetis an integral item. The polyethylene coating 8,9 is integral with thecardboard backing sheet 5,6 as part of the coating is diffused within orpenetrates into the cardboard backing sheet. It is important to notethat there is no adhesive between the coated backing sheets. There is nodistinct adhesive bead or layer between the coated backing sheets.

The sheets 5,6 are each decorated with printed information which canprovide information about a product held within the packaging and/or tomake the packaging aesthetically appealing.

The display package 4 further incorporates a third support layer in theform of a reinforcing sheet 10. The reinforcing sheet 10 is of acardboard which is stiffer than the cardboard of the front and backingsheets 5,6. In this preferred embodiment the reinforcing sheet 10 is ofcardboard which is thicker than the cardboard of the front and backingsheets 5,6. The purpose of the reinforcing sheet 10 will become clearfrom the description below.

The display package 4 further incorporates a clam in the form of an openended thermoplastic container 11. The container 11 is shaped to receivea product (not shown) which is to be retained within the display package4. The container 11 defines a mounting flange 12 which extends generallyperpendicularly outwardly around the side of the container 11, adjacentthe open end of the container 11.

A method of manufacturing the display package 4 will now be described.

Initially, the front and backing sheets 5,6 are coated with a layer ofthermoplastic and cut into an appropriate shape for packaging a product.If necessary, information and/or decoration is now printed onto thefront and backing sheets 5,6.

The front and backing sheets 5,6 and the reinforcing sheet 10 are cut tothe required size and shape using, for instance, a die cutting machineor a guillotine. The coated backing sheets 5,6 are therefore pre-formedelements.

A product is loaded into the container 11. Part of the container 11 ispushed through the aperture 7 in the front sheet 6 so that the mountingflange 12 is positioned against the coated region of thermoplastic 9 onthe front sheet 6 which surrounds the aperture 7.

The reinforcing sheet 10 is placed against one side of the front sheet 6adjacent, but spaced apart from, the aperture 7. The backing sheet isthen placed against the front sheet 6 so that the coated thermoplasticregion 8 of the backing sheet 5 is against and overlaps the coatedthermoplastic region 9 of the front sheet 6. The pre-formed coatedbacking sheets 5,6 are registered with one another. The mounting flange12 and the reinforcing sheet 10 are each sandwiched between the frontand backing sheets 5,6, as shown in FIGS. 3 and 5. It is important tonote that there is no adhesive between the coated backing sheets. Thereis no distinct adhesive bead or layer between the coated backing sheets.

The partially assembled display package 4 is loaded into a highfrequency welding machine. The high frequency welding machine operates,for example, at a radio frequency (RF). In this preferred embodiment,the high frequency welding machine is provided with a custom made jigwhich is shaped to receive the display package 4.

Referring now to FIG. 3 of the accompanying drawings, the high frequencywelding machine incorporates a first welding element 13 which ispositioned adjacent one side of the backing sheet 5 and a second weldingelement 14 which is positioned adjacent one side of the front sheet 6.The first and second welding elements 13,14 are positioned so as to beopposite one another, with the preformed coated backing sheets 5,6sandwiched between the elements 13,14. Once the welding elements 13,14are in position, the high frequency welding machine is activated so thathigh frequency radio waves are transmitted between the welding elements13,14. The high frequency radio waves pass through the sheets 5,6 andlayers of thermoplastic 8,9 which are positioned between the weldingelements 13,14. The high frequency radio waves interact only with theregions of the thermoplastic layers 8,9 between the welding elements13,14, causing the thermoplastic layers 8,9 to fuse together to form afused region 15, as shown in FIG. 4. The fused region 15 defines asecure connection between the front and backing sheets 5,6 whichattaches the sheets 5,6 together securely.

The high frequency welding machine is used to fuse together regions ofthe thermoplastic layers 8,9 around the entire periphery of the sheets5,6 so that the fused region 15 seals the front and backing sheets 5,6together, as shown by the outer dotted line 16 in FIG. 7.

The high frequency welding machine incorporates third and fourth weldingelements 17,18. The third and fourth welding elements 17,18 arepositioned respectively on each side of the first and second backingsheets 5,6, and on each side of the mounting flange 12 of the container11 which is sandwiched between the sheets 5,6, as shown in FIG. 5. Whenthe high frequency welding machine is activated, high frequency radiowaves pass between the third and fourth welding elements 17,18 to fuseregions of the layers of thermoplastic 8,9 and a region of the mountingflange 12 together to form a further fused region 19, as shown in FIG.6. The third and fourth welding elements 17,18 fuse regions of thethermoplastic layers 8,9 with regions of the mounting flange 12 aroundthe entire periphery of the mounting flange 12 to form a fused region asshown by the inner dotted line 19 in FIG. 7.

The fusing of the pre-formed polyethylene coated cardboard backingsheets 5,6 to one another is effected by RF welding the polyethylenecoatings together. If only one backing sheet was coated withpolyethylene, then the resultant bond is significantly less effectivethan when using two coated backing sheets. There is no adhesive betweenthe coated backing sheets. There is no distinct adhesive bead or layerbetween the coated backing sheets.

It is to be appreciated that, whilst the description above describesfirst and second and third and fourth welding elements, the highfrequency welding machine may incorporate a larger number of weldingelements which weld various regions of the thermoplastic layers 8,9 andthe mounting flange 12 together simultaneously. The high frequencywelding machine can thus attach the front and backing cards and thecontainer 11 together in one high frequency welding step. Using the RFwelding technique on polyethylene pre-coated and pre-formed cardboardbacking sheets is tremendously advantageous as there is no danger of theproduct being packaged being subjected to the high temperatures whichare necessary to provide an effective bond when a distinct adhesive isused between backing sheets. Prior art techniques consistently usetemperatures in excess of 400 degrees Celsius to cure a distinctadhesive bead or layer sandwiched between backing sheets. The heat mustpass through the backing sheets to reach and cure the sandwichedadhesive and this same heat may be damaging the packaged contents. Priortechniques also use more energy than the present invention to securelike bonds.

Referring now to FIG. 8 of the accompanying drawings, a furtherembodiment of the invention is in the form of a display card 20. Thedisplay card 20 is a simplified version of the display package 4 of thepreferred embodiment described above and common features between thedisplay card 20 and the display package 4 have been given the samereference numerals for ease of reference. The display card 20incorporates front and backing sheets 5,6 and a reinforcing sheet 10,but the display card 20 does not incorporate a container for containinga product. Each of the front and backing cards 5,6 of the display card20 is provided with an identically shaped hanging aperture 21,22.

The display card 20 of this further embodiment is manufactured byplacing thermoplastically coated regions of the front and backing cards5,6 together, with the reinforcing card 10 sandwiched between the sheets5,6. Regions of the thermoplastically coated layers of the sheets 5,6are then fused together by a high frequency welding machine. The fusedregions extend around the periphery of the sheets 5,6, as shown by thedotted line 23 in FIG. 9. The front and backing sheets 5,6 of thedisplay card 20 are thus attached securely to one another.

Whilst the embodiments described above each incorporate a reinforcingsheet 10, it is to be appreciated that the reinforcing sheet is optionaland other embodiments of the invention do not incorporate a reinforcingsheet. The inclusion of the reinforcing sheet is, however, preferred insituations when the container 11 contains larger items.

Embodiments of the present invention seek to provide the followingadvantages over prior proposed display packages.

The regions of the thermoplastic layers 8,9 and the regions of themounting flange 12 of the container 11 which are fused together by highfrequency welding are attached to one another very securely. The fusedconnection is difficult to break apart and hence display packagesmanufactured using the methods described above are very tamperresistant. The tamper resistance of display packages of preferredembodiments of the invention minimizes the possibility of the packagesbeing opened discretely by a thief and hence minimizes the possibilityof a packaged product being stolen by a thief.

The use of cardboard to form the front and backing sheets 5,6 isenvironmentally friendly since cardboard can be produced and disposed ofecologically. When coated with polyethylene the cardboard backing sheetsare used to create a package according to the invention. The resultantpackage is recyclable. If a distinct adhesive is used between backingsheets, then the resultant package is less susceptible to recycling.

The high frequency welding which is used in the manufacture of displaypackages 4,20 as described above does not generate heat. Themanufacturing process is thus suitable for packaging products, such asperfumes, which could otherwise be damaged by heat generated during mostprior proposed packaging methods.

The display packages and display card in accordance with embodiments ofthe invention have a neat appearance which is more aestheticallyappealing than most prior proposed packages.

The use of cardboard for both the front and backing sheets of packagesin accordance with embodiments of the invention maximizes the area onwhich information about the product can be displayed because informationcan be printed anywhere on the cardboard.

The method of manufacturing the display package in accordance withembodiments of the invention does not require the use of an adhesive.The components of the display package are fused to one another by highfrequency welding to produce a fused bond which is stronger than a bondformed using adhesive.

When used in this specification and claims, the terms “comprises” and“comprising” and variations thereof mean that the specified features,steps or integers are included. The terms are not to be interpreted toexclude the presence of other features, steps or components.

To summarize, the disclosure describes a method of manufacturing adisplay package (4) involving attaching thermoplastically coatedcardboard sheets (5,6) together by fusing regions of the thermoplasticcoating (8,9) together by high frequency welding. A containerincorporating a mounting flange is also fused to the thermoplasticlayers (8,9) by high frequency welding. There is no distinct adhesivebetween the polyethylene coated cardboard backing sheets.

Other embodiments of the present invention will be apparent to thoseskilled in the art after considering this disclosure or practicing thedisclosed invention. The specification and examples above are exemplaryonly, with the true scope of the present invention being determined bythe following claims.

1. A method of manufacturing a display package comprising: providing afirst cardboard element which has a first region that is coated with afirst layer of polyethylene; providing a second cardboard element whichhas a second region that is coated with a second layer of polyethylene;positioning the first and second cardboard elements such that the firstand second coated regions at least partly overlap; and attaching thefirst cardboard element to the second cardboard element by radiofrequency (RF) welding at least part of the first and second overlappingcoated regions such that the first and second coated regions at leastpartly fuse together.
 2. The method according to claim 1, whereininformation is printed on the first cardboard element.
 3. The methodaccording to claim 1, wherein information is printed on the secondcardboard element.
 4. The method according to claim 1, wherein themethod further comprises: providing a third element; and positioning thethird element between the first and second cardboard elements such thatthe third element is at least partly trapped between the first andsecond cardboard elements when the first and second cardboard elementsare attached to one another.
 5. The method according to claim 4, whereinthe third element is of cardboard.
 6. The method according to claim 1,wherein the first and second cardboard elements are each generallyplanar sheets, with one side of each of the sheets being substantiallyentirely coated with the layer of polyethylene.
 7. The method accordingto claim 1, wherein the method further comprises: providing an openended thermoplastic container which incorporates a mounting flange;placing a product into the container; positioning the mounting flange atleast partly between the overlapping coated regions of the first andsecond cardboard elements; and attaching the container to the cardboardelements by radio frequency (RF) welding at least part of the mountingflange to the coated regions such that the coated regions and themounting flange at least partly fuse together.
 8. The method accordingto claim 7, wherein the method further comprises: inserting part of thecontainer through an aperture in the second cardboard element andpositioning the mounting flange so as to overlap part of the coatedregion of the second cardboard element; and positioning the firstcardboard element to close the open end of the container such that thecontainer is sealed when the first cardboard element is attached to thesecond cardboard element.
 9. The method according to claim 1, whereinthe first and second cardboard elements are each coated on one side by alayer of polyethylene and the first and second cardboard elements arepre-formed for registration with one another to provide an effectivebond between the first and second cardboard elements.
 10. A displaypackage comprising: a first cardboard element which has a region that iscoated with a layer of polyethylene to form a first integral backingsheet; and a second cardboard element which has a region that is coatedwith a layer of polyethylene to form a second integral backing sheet;the first and second cardboard backing sheets being attached to oneanother by at least part of the coated region of the first cardboardelement which is at least partly fused to at least part of the coatedregion of the second cardboard element, wherein no adhesive is presentin any bond between the backing sheets.
 11. The display packageaccording to claim 10, wherein information is printed on the firstcardboard element.
 12. The display package according to claim 10,wherein information is printed on the second cardboard element.
 13. Thedisplay package according to claim 10, wherein the display packageincorporates a thermoplastic container which is at least partly fused tothe coated layer of the first cardboard element and the coated layer ofthe second cardboard element.
 14. A display package according to claim10, wherein the first and second cardboard elements each have apolyethylene coating on one side to provide an effective bond betweenthe first and second cardboard elements.
 15. A display package accordingto claim 10, wherein the first and second cardboard elements arepre-formed for registration with one another.